Method for use in a conveyor and a conveyor

ABSTRACT

The invention relates to a method for separating the web rolls ( 2 ) of a roll set ( 1 ) traveling on a conveyor ( 3 ) from each other. The conveyor ( 3 ) comprises a conveyor belt or chain ( 12 ) adapted to run about driving and tail pulleys ( 7 ). In the method, the set ( 1 ) of web rolls is transported on the leg of the conveyor belt or chain ( 12 ). According to the method, onto the top surface of the conveyor belt or chain ( 12 ) is formed an elevation capable of separating the web rolls ( 2 ) apart from each other with the help of an elevating roll assembly ( 5 ) adapted to operate below the top surface of the conveyor belt or chain ( 12 ) and comprising at least one rotary elevating roll ( 6 ).

The present invention relates to a method according to the preamble ofclaim 1 for separating web rolls on a conveyor from each other.

The invention also relates to a roll conveyor suited for implementingthe method.

Web rolls manufactured on a paper or paperboard machine are slit at aslitter-winder from a wide machine roll into rolls of narrower widthaccording to customer order. Slitter-winders fall into two main types:shaft-supported slitter-winders, in which the slit rolls are deliveredfrom the slitter in two different sets to both sides of the winder, andsurface-driven slitter-winders, in which the slit rolls are delivered asa complete set. Since surface-driven belt-supported slitter-winders arebased on the same principle as surface-driven roller-supportedslitter-winders, in a general sense it is appropriate in this context toassign the term “surface driven slitter-winder” to any winder-slittercapable of delivering the rolls as a complete set.

Rolls manufactured on a surface-driven slitter-winder must be separatedfrom each other for such reasons as, e.g., quality checks, before theslit rolls can be transferred further to a labeling and packagingstation. Conventionally, the rolls of a roll set delivered by theslitter-winder are separated from each other at a transition pointbetween two roll conveyor sections. When the separation point betweenthe first and second roll of a roll set coincides with the transitionpoint between the conveyor sections, the first conveyor is stopped,whereby the first roll of the set continues its travel on the secondconveyor, while the other rolls of the set remain on the first conveyor.Subsequently, the separation point between the second and third roll isdriven to the transition point between the conveyor sections, whereuponthe first conveyor is stopped causing the second roll to continue itstravel on the second conveyor, while the other rolls of the set remainon the first conveyor. The same sequence is repeated until all of therolls of the set are separated from each other.

The rolls of a set received from a slitter-winder may stay adhered toeach other due to different reasons: the core ends are not flush withthe web roll ends, the sheet edges of the rolls are slit uneven leavingthem interleaved with each other or slitting has been started too latewhereby the core still has some layers unslit. If the rolls adhere toeach other, problems may occur at the transition point between theconveyors in the case that the rolls fail to separate. To avoid suchcomplications, full separation of rolls must be checked in a setreceived from a surface-driven slitter-winder. While checking theseparation of rolls in a set may occur at any place along the transferof the roll set, generally the check is performed through arching theroll set by way of elevating the middle rolls of the roll set upward somuch that the roll ends separate from each other leaving a gaptherebetween. At this moment, the operator checks visually that allrolls are separated from each other and, if necessary, uses a wedge toforce apart any rolls adhering to each other. Although modernslitter-winders are extensively automated, yet monitoring the rolls in aroll set and separation of the rolls from each other are operation stillbeing performed manually. These worksteps prevent running aslitter-winder with lesser manpower. In addition to being monotonous andtedious, such operator tasks may be even hazardous if carried outcounter to instructions or by negligence. Sufficient time must also bereserved for the operator's actions to permit his checks on the roll setto be performed safely. Due to the manual separation of rolls, theoperation of the slitter-winder and the roll conveyor system is sloweddown.

It is an object of the present invention to provide a novel method forseparating rolls of a roll set received from a slitter-winder apart fromeach other without the need for mechanical intervention by the operator.It is a further object of the invention to provide a conveyor capable ofimplementing the method.

The goal of the invention is attained by virtue of separating the rollsof a roll set resting on a conveyor with the help of an elevating rollassembly that is situated under the conveyor chain or belt and comprisesat least one freely rotating elevating roll. The elevating roll assemblyforms on the top surface of the conveyor chain or belt an elevationdirected upward. As the rolls travel over the elevation, the end-to-endabutting web rolls of the roll set are deflected in regard to eachother, whereby any adhering rolls are separated from each other. Theseparating effect is augmented by the forces generated by the smallspeed difference between the web roll lifted onto the elevation andthose traveling on the base level of the conveyor belt or chain.Additionally, the shape of the conveyor chain slats and/or elevatingrolls puts the conveyor chain or belt into a reciprocating up and downmotion that detaches the adhering web rolls from each other.

More specifically, the method according to the invention ischaracterized by what is stated in the characterizing part of claim 1.

Furthermore, the roll conveyor according to the invention ischaracterized by what is stated in the characterizing part of claim 4.

The invention provides significant benefits.

Now automated separation of web rolls in a set becomes possible thusreducing the number of mechanical and tedious operations the personnelhave to perform in a close vicinity of the rolls. Additionally, theoperation of the slitter-winder as well as the roll conveyor system isaccelerated, since the system need not be stopped for separating therolls of a set. The embodiment according to the invention also has asimple construction that can be readily installed on existing rollconveyor layouts.

In the following, the invention is examined in more detail with the helpof the appended drawings.

FIG. 1 is a top view of a set of web rolls received onto a roll conveyorfrom a slitter-winder.

FIG. 2 is a sectional view of FIG. 1 taken along plane A-A.

FIG. 3 is a partially enlarged view of FIG. 2 taken at point C having anelevating coveyor roll assembly adapted below the top level of theconveyor chain.

FIG. 4 is a sectional view of FIG. 3 taken along plane B-B.

FIG. 5 is a schematic side elevation view of the top level of a conveyorchain or belt at the elevating roll assembly.

Referring to FIG. 1, therein is shown the travel of paper or paperboardweb rolls 2 of a roll set 1 received from a slitter-winder 11 of paperor paperboard machine as the rolls gravitationally move along a downwardramp 9 until the rolls are stopped onto a conveyor 3 by a stop gage. Therolls of the roll set 1 rest on the conveyor 3 with their ends abuttingeach other and the center axes aligned in the transport direction ofconveyor 3. The transport direction of conveyor 3 is designated by arrow10 in FIGS. 1 and 2. The rolls 2 have the underside of theircircumferential periphery resting against the top surface of theconveyor chain or belt 12 of conveyor 3. After the rolls of roll set 1are stopped onto conveyor 3, they are separated from each other at thetransition point between the conveyor 3 and an other conveyor 4. Theseparation of rolls 2 from each other takes place by way of moving theset 1 of web rolls on conveyor 3 toward the second conveyor 4 until theabutment plane between the first and second roll of set 1 coincides withthe transition point of the conveyor 3 and the other conveyor 4. At thisinstant, the conveyor 3 is stopped whereby the first roll of set 1continues its travel on the other conveyor 4. Subsequently, the roll setis moved on the conveyor 3 so that the abutment plane between the secondand third roll of the set coincides with the transition point of thefirst conveyor 3 and the other conveyor 4, whereupon the conveyor 3 isstopped and the second roll of the set continues its travel on the otherconveyor 4. The sequence is continued until all the rolls 2 of set 1 areseparated from each other.

Typically, conveyor 3 is a slat conveyor. Adapted moving about drivingand tail pulleys 7 is an endless conveyor link chain loop 12 comprisingtwo parallel-running lateral chains connected to each other by slats 8.In the endless conveyor chain 12, the long sides of the transverse slats8 are shaped so that recesses 13 remain between the adjacent slats 8.The driving and tail pulleys 7 have teeth adapted to fit between thelinks of the lateral chains thus facilitating transmission of thedriving pulley rotation into a linear motion of conveyor chain 12. Asshown in FIG. 4, the slats 8 are slightly shaped in a V-angle thusmaking the slats 8 when running on the top leg of the conveyor chain toslant downward from the ends of the slat toward the center of the slat.

To separate adhering web rolls 2 of a roll set 1 from each other,conveyor 3 is provided with an elevating roll assembly 5 comprising atleast one freely rotating elevating roll 6. Typically, the elevatingroll assembly 5 includes two to four elevating rolls 6 adapted tooperate in succession along the travel direction 10 of conveyor 3. In apreferred embodiment of the invention illustrated in the drawings, thenumber of the successive elevating rolls 6 is two.

The elevating roll assembly 5 is adapted between the top leg and bottomleg of the endless loop chain of conveyor 3 so that the top leg of theconveyor chain is elevated at the elevating rolls 6 by a fewmillimeters, typically 2 to 6 mm, from the base level 14 of the conveyorchain top leg. The outer surfaces of the elevating rolls 6 are coveredby an elastic lining such as polyurethane. Each one of the elevatingrolls 6 is comprised of two wheels 15 aligned parallel to each other inthe travel direction of conveyor 3, the wheels having disposedtherebetween a spacer member 16 with a diameter smaller than that of thewheels 15. The spacer member 16 is mounted on the conveyor frame and thewheels are respectively mounted in bearings on the spacer member 16. Theelevating roll 6 is placed under the top leg of the endless loopconveyor 3 so that the center point of the top leg of the conveyor chainrelative to the lateral dimension of the conveyor chain 12, that is, thecenter valley point of the V-angled slats 8, coincides with the spacermember 16 and the wheels 15 run symmetrically on both sides of theconveyor chain center line. The peripheral diameters of wheels 15 aretapered toward the conveyor chain center line thus making them morecompliant to the V-angled shape of slats 8. The center points of slats 8do not touch the spacer member 16. To support the top surface ofconveyor chain 12, the lateral chains are provided with support wheels18 that run along rails 17 mounted on the frame of conveyor 3. Thesupport wheels are arranged to operate in two adjacent rows in regard tothe travel direction 10 of conveyor 3. Wheels 15 of elevating roll 6 andthe spacer member 16 mounted therebetween are adapted between thesupport wheel rows.

If the number of the elevating rolls 6 is two or more, the mutualdistance d₁ between the shafts of the successive elevating rolls 6 isabout 125 mm. When using, e.g., two elevating rolls 6, this makes thelength d₂ of the elevation formed by the elevating rolls 6 on the topleg of the conveyor leg to be about 200 mm. The length of the elevationis determined by the number and diameter of the elevating rolls 6, aswell as the mutual spacing between the successive elevating rolls. In aconveyor equipped with two elevating rolls 6, the length d₂ of theelevation is typically 150 to 200 mm.

The separating motion imposed on the paper web rolls 2 resting on thetop leg of the chain of conveyor 3 supported by the elevating rollassembly 5 is illustrated in more detail in FIG. 5. The abutting ends ofsuccessive paper web rolls 2 are angled four times in regard to eachother as they pass over the elevation formed by the elevating rollassembly 5 on the top leg of the conveyor chain. Each deflectionpromotes the separation of the paper web rolls 2 from each other. Thefirst deflection occurs when the paper web roll meets theupward-slanting portion 19 of the top leg of conveyor chain 12, whilethe next following web roll still rests on the base level 14 of theconveyor chain top leg. The second deflection occurs when the paper webroll falls onto conveyor chain portion 20 running on the elevating rolls6 of the conveyor chain top leg. The web rolls are angled mutually thethird time when the web roll falls onto the downward-slanting portion 21of the conveyor chain. The fourth deflection occurs when the web rolllands onto the conveyor chain base level 14 following the elevatingrolls.

In addition to the bending force imposed on the web rolls of a set, therolls are subjected to a reciprocating up and down movement as theelevating rolls alternatingly sink into the elongated recesses 13between the adjacent slats 8 and then again hit the projections of thelower surfaces of the slats 8. The travel speed of the chain top leg ofconveyor 3 is slightly different on the base level 14 (v1) of the chaintop leg as compared to the conveyor speed (v2) on the chain portion 20running on the elevating rolls 6. Due to the instantaneously fastertransport speed of the paper web roll on the chain portion 20 passingover the elevating rolls 6 as compared to the roll transport speed onthe conveyor's flat portion, that is, the base level 14 of the conveyor,also this speed difference imparts a separating effect on the adheringweb rolls.

The invention may have embodiments different from those described above.

The separating effect can be enhanced by providing the conveyor chaintop level with several elevations by adapting plural elevating rollassemblies along the travel length of conveyor 3.

The invention may also be utilized in other types of conveyors. If theconveyor is a belt conveyor or flat slat conveyor having the slatsshaped shallower than those of the above-discussed roll conveyor,whereby a sufficiently wide elongated recess is not provided betweenadjacent slats, the reciprocating up and down motion can be accomplishedby means of a suitably designed shape of the elevating rolls 6. To thisend, the periphery of the elevating rolls 6 may have, e.g., a polygonalor elliptic shape or, alternatively, the elevating rolls 6 may beadapted to rotate eccentrically.

The spacer members 16 between the elevating rolls 6 may be complementedwith actuators allowing the elevation height formed by the elevatingrolls 6 to be adjustable during the operation of conveyor 3.

1-10. (canceled)
 11. A method for separating rolls of a roll settraveling on a conveyor from each other, the conveyor comprising aconveyor belt or chain running about driving and tail pulleys,comprising: transporting the roll set on a top surface of said conveyorbelt or chain; forming onto the top surface of the conveyor belt orchain an elevation sufficient to separate the rolls from each other whenthe rolls of the roll set are transported over the elevation.
 12. Themethod of claim 11, wherein the elevation is formed with an elevatingroll assembly adapted to operate below the top surface of the conveyorbelt or chain and comprising at least one rotary elevating roll.
 13. Themethod of claim 11, wherein a height of elevation between the topsurface of a base level of the conveyor belt or chain and a top level ofthe elevation is adjusted during operation of the conveyor, the baselevel of the conveyor being a level of the conveyor upstream of theelevation.
 14. The method of claim 12, wherein a height of elevationbetween the top surface of a base level of the conveyor belt or chainand a top level of the elevation is adjusted during operation of theconveyor, the base level of the conveyor being a level of the conveyorupstream of the elevation.
 15. The method of claim 12, wherein at leastone of the at least one elevating roll is a polygonal elevating roll.16. The method of claim 12, wherein at least one of the at least oneelevating roll is an elliptic elevating roll.
 17. The method of claim12, wherein at least one of the at least one elevating roll is a rollrotating eccentrically.
 18. The method of claim 14, wherein at least oneof the at least one elevating roll is a polygonal elevating roll. 19.The method of claim 14, wherein at least one of the at least oneelevating roll is an elliptic elevating roll.
 20. The method of claim14, wherein at least one of the at least one elevating roll is a rollrotating eccentrically.
 21. A conveyor for transporting a roll set,comprising: a conveyor belt or chain running about driving and tailpulleys, the conveyor belt or change being configured to support a rollset on a top surface thereof; an elevating roll assembly positionedbelow a portion of the top surface of the conveyor belt or chain andoperable to form on the top surface of the conveyor belt or chain anelevation sufficient to separate the rolls of the roll set from eachother when the rolls of the roll set are transported by the conveyorbelt or chain over the elevation.
 22. The conveyor of claim 21, whereinthe elevating roll assembly comprises at least one rotatably mountedelevating roll.
 23. The conveyor of claim 22, wherein the elevating rollassembly comprises two elevating rolls adapted to operate in successionalong a travel direction of the conveyor.
 24. The conveyor of claim 22,wherein the at least one elevating roll is a polygonal elevating roll.25. The conveyor of claim 22, wherein the at least one elevating roll isan elliptic elevating roll.
 26. The conveyor of claim 22, wherein the atleast one elevating roll is a roll rotating eccentrically.
 27. Theconveyor of claim 23, wherein at least one of the elevating rolls is apolygonal elevating roll.
 28. The conveyor of claim 23, wherein at leastone of the elevating rolls is an elliptic elevating roll.
 29. Theconveyor of claim 23, wherein at least one of the elevating rolls is aroll rotating eccentrically.
 30. The conveyor of claim 21, wherein aheight difference between the top surface of a base level of theconveyor belt or chain and the top level of the conveyor elevation is 2to 6 mm, the base level of the conveyor being a level of the conveyorupstream of the elevation.
 31. The conveyor of claim 22, wherein aheight difference between the top surface of a base level of theconveyor belt or chain and the top level of the conveyor elevation is 2to 6 mm, the base level of the conveyor being a level of the conveyorupstream of the elevation.
 32. The conveyor of claim 23, wherein aheight difference between the top surface of a base level of theconveyor belt or chain and the top level of the conveyor elevation is 2to 6 mm, the base level of the conveyor being a level of the conveyorupstream of the elevation.
 33. The conveyor of claim 21, furthercomprising a means for adjusting the elevation.
 34. The conveyor ofclaim 22, further comprising a means for adjusting the elevation. 35.The conveyor of claim 21, wherein the elevating roll comprises twowheels and a spacer member, one of the two wheels being on each side ofa longitudinal center line of the conveyor belt or chain, the two wheelsbeing rotatably supported with as the spacer member mountedtherebetween.
 36. The conveyor of claim 22, wherein the elevating rollcomprises two wheels and a spacer member, one of the two wheels being oneach side of a longitudinal center line of the conveyor belt or chain,the two wheels being rotatably supported with as the spacer membermounted therebetween.
 37. The conveyor of claim 21, wherein a length ofthe elevation in a direction of travel of the conveyor belt or chain is150 to 250 mm.
 38. The conveyor of claim 23, wherein a length of theelevation in a direction of travel of the conveyor belt or chain is 150to 250 mm.
 39. The conveyor of claim 30, wherein a length of theelevation in a direction of travel of the conveyor belt or chain is 150to 250 mm.
 40. The conveyor of claim 31, wherein a length of theelevation in a direction of travel of the conveyor belt or chain is 150to 250 mm.